Gummy Candy

Background

Gummy candy is a unique candy composed of gelatin, sweeteners, flavorings,
and colorings. Because of its nature it can be molded into literally
thousands of shapes, making it one of the most versatile confection
products ever. First developed in Germany in the early 1900s, it gained
great popularity in the United States during the 1980s. Today, it
continues to be popular, with sales totaling over $135 million in 1996 in
the United States alone.

History

Gummy candy represents a more recent advance in candy technology. The
technology, derived from early pectin and starch formulations, was first
developed in Germany in the early l900s by a man named Hans Riegel. He
began the Haribo company, which made the first gummy bears in the 1920s.
While gummy candy has been manufactured since this time, it had limited
worldwide distribution until the early 1980s. It was then when Haribo
began manufacturing gummy bears in the United States. The fad caught on,
causing other companies to develop similar products. The gummy bears led
to other types of gummy candy entries from companies such as Hershey,
Brach's, and Farley's. Now, the candy is available in
various different forms, from dinosaurs to fruit rolls. According to one
gelatin manufacturer, nearly half of all gelatin made worldwide currently
goes to making gummy candies.

Raw Materials

Gummy candy recipes are typically developed by experienced food
technologists and chemists. By blending together different ingredients,
they can control the various characteristics of gummy candy, such as
texture, taste, and appearance. The primary ingredients include water,
gelatin, sweeteners, flavors, and colors.

The main ingredient responsible for the candy's unique, gummy
characteristics is gelatin. This is a protein derived from animal tissue
that forms thick solutions or gels when placed in water. When used at an
appropriate concentration, the gels take on the texture of the chewy,
gummy candy. However, since these gels are thermoreversible, which means
they get thinner as they are heated, gummy candies have a "melt in
the mouth" characteristic. Both the texture and the amount of time
it takes the candy to dissolve in the mouth can be controlled by the
amount of gelatin used in a recipe.

Since gelatin is a tasteless and odorless compound that contains no fat,
sweeteners and flavorings are added to give gummy candy its taste. Various
sugars are added as sweeteners. Sucrose, derived from beets or sugar cane,
provides a high degree of sweetness to the gummy candy. Fructose, which is
significantly sweeter than common sucrose, is another sugar that is often
used. Corn syrup is also used because it helps prevent the other sugars
from crystallizing and ruining the gummy texture. Also, corn syrup helps
add body to the candy, maintain moisture, and keep costs lower. Another
sweetener is sorbitol, which has the added benefit of helping the candy
maintain its moisture content. In addition to flavor, some of these
sweeteners have the added benefit of preserving the gummy candy from
microbial growth.

The sweetness of gummy candy is only one of its characteristics.
Artificial and natural flavors are also used to create a unique taste.
Natural flavors are obtained from fruits, berries, honey, molasses, and
maple sugar. The impact of these flavors can be improved by the addition
of artificial flavors that are mixtures of aromatic chemicals and include
materials such as methyl anthranilate and ethyl caproate. Also, acids such
as citric acid, lactic acid, and malic acid are added to provide flavor.

Gelatin gels have a natural faint yellow color, so dyes are added to
create the wide array of colors found in gummy candy. Typical dyes include
Red dye #40, Yellow dye #5, Yellow dye #6, and Blue dye #1. Using these
federally regulated dyes, gummy manufacturers can make the candy almost
any color they desire.

The textural characteristics of gelatin gels depends on many factors, such
as temperature, method of manufacture, and pH. While the manufacturing
method and temperature can be physically controlled, the pH is controlled
chemically by the addition of acids. These include food grade acids such
as citric acid, lactic acid, fumaric acid, and malic acid. Other
ingredients are added during the manufacturing process as flavorants,
lubricating agents, and shine enhancing agents. These include materials
like beeswax, coconut oil, carnauba wax, mineral oil, partially
hydrogenated soybean oil, pear concentrate, and confectioner's
glaze, which are often added during the filling phase of manufacture.

The Manufacturing
Process

Gummy manufacturing uses a starch molding process. First the candy is
made, then it is filled into starched lined trays. The filled trays are
then cooled overmight and the resulting formed candy is emptied from the
trays. In the mass production of gummy candy, significant improvements
have been made to increase the speed and efficiency of this process.

Compounding

1 The manufacture of gummy candy begins with compounding. Factory
workers, known as compounders, follow instructions outlined in the
recipes and physically pour the appropriate amount of gummy raw
materials into the main mixing tanks. These tanks, which are equipped
with mixing, heating, and cooling capabilities, are quite large.
Depending on the size of the batch, gummy candy compounding can take
from one to three hours. When the batch is complete, it is sent to the
Quality Control (QC) laboratory to make sure that it meets the required
specifications.

Forming candy

2 After the gummy candy is compounded and passes QC testing, it is
either pumped or transferred to a starch molding machine known as a
Mogul. This machine can automatically perform the multiple tasks
involved in making gummy candy. It is called a starch molding machine
because starch is a main component. In this machine, starch has three
primary purposes. First, it prevents the candy from sticking to the
candy molds, which allows for easy removal and handling. Second, it
holds the gummy candy in place during the drying, cooling, and setting
processes. Finally, it absorbs moisture from the candies, giving them
the proper texture.

3 Making gummy candy in a Mogul is a continuous process. At the start of
the machine, trays that contain previously filled, cooled, and formed
gummy candy are stacked. The trays are then removed from the stack
one-by-one and iwove along a conveyor belt into the next section of the
machine, known as the starch buck.

4 As they enter the starch buck, the trays are inverted and the gummy
candy falls out into a vibrating metal screen known as a sieve. The
vibrating action of the sieve, in concert with oscillating brushes,
removes all of the excess starch that adheres to the gummy candy. These
pieces then move along a conveyor belt to trays, where they are manually
transferred to other machines by which they can be decorated further and
placed into appropriate packaging. A more recent advance, called the
pneumatic starch buck, further automates this step. In this device, a
tightly fitting cover is placed over the filled trays. When it is
inverted, the candies adhere to the cover and remain in their

Gummy candy is manufactured in a machine called a Mogul. Cooled
trays of gummy candy are inverted in the starch buck. This candy is
ready for packaging. The trays are then filled with starch to keep
the candy from sticking and sent to the printer table, which
imprints a pattern into the starch. The depositor fills the trays
with the hot candy mixture, and the trays are sent back to the
stacker to cool for 24 hours. Then the machine can start the process
again.

ordered position. The excess starch is then removed by fast-rotating
compressed-air jets. The candy can then be conveyed for further
processing.

5 The starch that is removed from the gummy candy is reused in the
process, but first it must be cleaned, dried, and otherwise
reconditioned. Candy particles are first removed by passing the starch
through a metal screen known as a sieve. It is then conveyed to a
recirculating starch conditioning system. As it enters this machine, it
is dried by being passed through hot, moving air. After drying, the
starch is cooled by cool air jets and conveyed back out to the Mogul to
be reused in the starch molding process.

6 The starch returns from the drier via a conveyor belt to the Mogul,
where it is filled into the empty trays and leveled. These were the same
trays that were inverted and emptied in step two. These starch-filled
trays then move to a printer table. Here, a board that has the inverse
of the mold printed on it presses the starch down so the mold has an
indent in it. From here, the trays are moved to the depositors.

7 The gummy candy, compounded in step 1, is transferred to the
depositors. This is the part of the mogul that has a filling nozzle and
can deliver the exact amount of candy needed into the trays as they pass
under it. The depositor section of the mogul can contain 30 or more
depositors, depending on how many imprints there are on the trays. In
more modern depositors, the color, flavor, and acids can be added to the
gummy base right in the depositor. This allows different colors and
flavors to be made simultaneously, speeding up the process.

8 The filled trays are moved along to a stacking machine and then sent
to a cooling room, where they stay until they are appropriately cooled
and formed. This part of the process can take over 24 hours. After this
happens, the trays are moved back to the Mogul, and the process starts
all over again.

Quality Control

Quality control begins with the evaluation of the incoming raw materials.
Before they are used, these ingredients are tested in the QC lab to ensure
they conform to specifications. Various sensory characteristics are
checked, including appearance, color, odor, and flavor. Many other
characteristics, such as the particle size of the solids, viscosity of
oils, and pH of liquids, are also studied. Each manufacturer depends on
these tests to certify that the ingredients will produce a consistent,
quality batch of gummy candy.

The characteristics of each batch of final product is also carefully
monitored. Quality control chemists and technicians check physical aspects
of the candy that include appearance, flavor, texture, and odor. The usual
method of testing is to compare them to an established standard. For
example, the color of a random sample is compared to a standard set during
product development. Other qualities such as taste, texture, and odor are
evaluated by sensory panels. These are made up of a group of people who
are specially trained to notice small differences. In addition to sensory
tests, many instrumental tests that have been developed by the industry
over the years are also used to complement tests performed by humans.

The Future

Increasing the safety, speed, and efficiency of the manufacturing process
are the major improvements being investigated for the future of the gummy
candy industry. In any starch molding process, safety is a major concern
because starch dryers represent an explosion hazard. Currently the U.S.
government recommends minimizing these hazards by using spark-proof
switches, blast walls, and other such mechanisms. Newer starch drying
machines represent a reduced explosion hazard and improved microbiological
killing. Additionally, moguls are being constructed that operate faster
and more efficiently.

Since new products are the lifeline of any company in the candy business,
new gummy flavors and colors are constantly being added to the base
formula. Also, unique shapes are being molded, creating a plethora of new
gummy candy. New forms of gummy candy are also being developed, most
recently, a combination of gummy candy and marshmallow.

Where to Learn More

Books

Traxler, Hans.
The Life and Times Of Gummy Bears.
Harper Collins, 1993.

After filling the candy mixture in moulds-1)At what temperature gummy candies are cooled & what is duration(how much time) of cooling? 2)What are atmospheric conditions maintained in drying rooms i.e. How much temperature and humidity maintained(required) for drying of gummy candies? 3)what is duration of drying the gummy candies in drying rooms?

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